Replacement of a front lower control arm on a 2024 Tesla Model S Long Range AWD. This is a non-HV chassis job, but Tesla-specific lifting points and aluminum body cautions apply.

Warnings

Tools required

Parts

• Front lower control arm assembly (manufacturer-specified for 2024 Model S LR AWD) × 1 — OEM Tesla front LCA — verify by VIN
• Ball joint nut (single-use if specified by manufacturer) × 1 — OEM-spec self-locking nut
• Control arm pivot bolts/nuts (replace if specified as single-use) × 1 — OEM-spec fasteners

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with the key fob away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Disconnect the 12V low-voltage battery. On 2024 Model S it is located in the front trunk (frunk) under the nose cowl panel; some Plaid units use a 16V Li-ion pack — verify before disconnecting.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
5. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
6. If the vehicle has air suspension, enable Jack Mode on the touchscreen (Controls > Service > Jack Mode) BEFORE lifting.
7. Loosen the front wheel lug nuts while the vehicle is still on the ground.
8. Lift the vehicle using only Tesla-approved lift points with rubber pucks; never lift on the battery case or pinch welds without a puck.
9. Support the vehicle with rated jack stands. Confirm stability before going underneath.

Procedure

1. 1

   Remove front wheel
   Remove the lug nuts and pull the front wheel off the side being serviced. Set the wheel aside on its sidewall to protect the finish.
2. 2

   Inspect and photograph
   Photograph the existing control arm orientation, bushing alignment, and any cam/eccentric bolt marks. This aids reassembly and pre-alignment positioning.
3. 3

   Disconnect sway bar end link
   Hold the sway bar link shaft with an Allen key while loosening the nut to prevent the stud from spinning. Separate the link from the control arm or strut as applicable.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Support the knuckle
   Place a jack under the steering knuckle or hub assembly to support it once the ball joint is released. Do not let the knuckle hang — this can damage the CV axle, ABS sensor wiring, or brake hose.
   ⚠Do not pull the CV axle out of the transmission/drive unit — it is sealed and not part of this job.
5. 5

   Separate ball joint from knuckle
   Remove the ball joint nut securing the lower control arm to the steering knuckle. Use a ball joint separator tool to release the taper. Avoid hammering directly on aluminum knuckle ears.
   ⚠Aluminum knuckle — do not pry or hammer aggressively. Use a proper separator.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
6. 6

   Remove control arm pivot bolts
   Remove the inboard pivot bolt(s) securing the lower control arm to the front subframe/cradle. Note the orientation of any cam washers or alignment marks. Support the arm as the last bolt comes out.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Remove control arm
   Maneuver the old lower control arm out from under the vehicle. Compare the new arm side-by-side to the old one to confirm correct part, bushing orientation, and ball joint stud direction.
8. 8

   Install new control arm — inboard pivot
   Position the new lower control arm and start the inboard pivot bolt(s) by hand. Do NOT fully torque yet — leave snug only. Final torque must be applied at ride height.
   ⚠Final torque on bushings at full droop will pre-load the rubber and shorten arm life dramatically.
9. 9

   Reconnect ball joint to knuckle
   Insert the ball joint stud into the steering knuckle, install the nut, and torque to specification. Use a new self-locking nut if specified by the manufacturer.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Reconnect sway bar end link
    Reinstall the sway bar link to the control arm or strut. Hold the shaft with an Allen key and torque the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
11. 11

    Reinstall wheel
    Mount the wheel and start all lug nuts by hand. Snug in a star pattern, then lower the vehicle to the ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
12. 12

    Final torque control arm pivot bolts at ride height
    With the full vehicle weight on the wheels (on ground or on drive-on ramps), torque the inboard control arm pivot bolts to specification. This sets the bushing in its neutral, loaded position.
    ⚠Critical step — skipping this guarantees premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Final lug torque
    Torque all lug nuts to specification in a star pattern with vehicle on the ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Confirm sway bar link, ball joint nut, and wheel lugs are all torqued to spec.
2. Verify final torque on inboard control arm pivot bolts was completed at ride height, not at full droop.
3. Reconnect the 12V (or 16V) low-voltage battery in the frunk; reinstall the cowl/cover.
4. If air suspension equipped, exit Jack Mode by driving above ~7 mph or via the touchscreen.
5. Cycle ignition and confirm no chassis, ABS, or stability control faults on the instrument cluster.
6. Clear any transient alerts on the touchscreen.

Verification

• Test drive at low speed first; listen for clunks over bumps that would indicate a loose pivot bolt or bushing.
• Verify steering centers correctly and the vehicle does not pull. A pull or off-center wheel is normal until alignment is performed.
• Schedule a 4-wheel alignment immediately — required after any control arm service on Model S.
• After 50–100 miles, re-check ball joint nut and pivot bolt torque.
• While the vehicle is up, take this opportunity to inspect: brake fluid age (Tesla recommends replacement every 2 years), cabin air filter age (every 2 years, or 3 years if HEPA), tire rotation interval (every 6,250 mi), and front drive unit fluid service status (initial 12,500 mi, then per Tesla's revised interval guidance).

More procedures for this vehicle